Modular counterflow fill hanging system apparatus and method

ABSTRACT

A heat exchange fill apparatus for use with a cooling tower that employs a support frame assembly. The heat exchange fill apparatus has a media fill pack that is comprised of fill pack media modules wherein a stake, prevents the modules from shifting with respect to one another. The modules are installed in a cooling tower of the like via a hanging fill support

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and is a divisional of U.S. patentapplication entitled, MODULAR COUNTERFLOW FILL HANGING SYSTEM APPARATUSAND METHOD, filed Jan. 24, 2014, having a Ser. No. 14/163,579, thedisclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to a hanging film fill pack foruse for heat exchange in a cooling tower or the like. More particularly,the present invention relates to a modular hanging fill pack design andmethod that is efficient and economical to assemble and install in acooling tower.

BACKGROUND OF THE INVENTION

Industrial water cooling towers have long been used to reject heat inpower generation, to provide cooling water for petrochemical processes,industrial processes or the like, and serve as a means to lower thetemperature of various chemical process streams and equipment. In thecase of power generation plants, the cooling tower requirements can berelatively large and it is often times the practice to fabricateincreasingly larger cooling towers. Counterflow towers have been foundto be especially useful in these instances because of the efficiency ofthe towers and the compact nature of the structure. Cooling air may bebrought into heat exchange relationship with the hot water either by wayof convection through use of a natural draft stack, or by means of oneor more large diameter, power-driven fans.

In order to further increase the efficiency of cooling towers forindustrial applications which require the use of very large towers,efforts have been made to increase the effectiveness of heat exchangebetween the hot water and the cooling air. The degree of direct contactof the water to be cooled with the coolant air has a significant bearingon the efficiency of the cooling process. Counterflow towers, whereinthe hot water and air are brought into countercurrent flow relationshiphave long been known to be efficient heat transfer units. Initial eggcrate or slat splash bar towers were ultimately supplanted by film filltowers because of the greater heat transfer properties of a water filmas compared with the multiplicity of droplets of water which areproduced by splash fills. Furthermore, film fills are typicallysignificantly shorter than splash fills thus decreasing the head on thepump delivering hot water to the tower and making operating lessexpensive because of the lower horsepower pump requirements.

The superior heat transfer characteristics of counterflow towers as wellas improved efficiency based on lower pump heads has increased theirdesired use in industrial applications. Cooling tower designers inseeking to increase the efficiency of counterflow towers have alsosought to further decrease the overall height of such towers by makingthe fill more effective than has been the case in the past. With theadvent of synthetic resin sheets which are capable of withstandinghigher temperatures without significant deformation than was previouslythe case, along with the development of resin formulations which aremore resistant to deterioration under constant wet conditions, fillassemblies made up of sheets of the plastic for film flow of waterthereover have in many instances completely supplanted prior fillstructures which primarily relied upon break-up of the water for surfaceincrease purposes instead of thin films of water over a largemultiplicity of closely spaced sheets of plastic.

Although film fills have found acceptance in many applications includinglarge industrial cooling towers for power generating plants and thelike, problems have arisen by virtue of the fact that governmentalregulatory agencies have imposed stricter limitations on the addition ofagents to the cooling water which suppress growth of microorganisms andthe like. For example, it has long been the practice to add chlorine orchlorine containing compounds to the cooling water in order to preventmicroorganism growth. However, it is now known that when chlorine inhigh concentrations is discharged into streams or other natural bodiesof water, the chlorine can produce adverse consequences which areharmful to biological life in the stream and in general increase whatsome deem to be undesirable pollution of the flowing water.

Cooling tower operators have routinely removed a portion of the coolingtower water in the form of blow down and returned it to the source suchas a stream to prevent buildup of chemical additives in the water. Asmuch as 10% of the water may be continuously returned to the stream orother water source as blow down. This water can contain a relativelyhigh concentration of the additive and therefore significant amounts ofchlorine, for example, may be present at the outlet of the cooling towerwhich discharges into the adjacent stream, lagoon, or lake water source.Concern over stream and water body pollution has led governmentalauthorities to restrict the use of additives such as chlorine in coolingtower water for preventing growth of microorganisms in the recirculatingcooling water. In fact, absent a more acceptable anti-microbial additivethan chlorine and which is available at a reasonable cost, many toweroperators have elected to simply eliminate or drastically reduce theadditives such as chlorine in the cooling tower water.

The result of the above discussed regulations is the build up ofmicroorganism growth in the flow assembly of counterflow industrialwater cooling towers. One highly effective and efficient fill assemblyfor counterflow towers employs corrugated plastic sheets, howevermicroorganisms can proliferate in such fills. As the water to be cooledflows downwardly through the corrugated fill structure, microorganismspresent in the water and whose growth is no longer inhibited by suitableanti-microbial compounds in the water, collect at the points ofintersection of the corrugations of the fill. The microorganisms thenstart to multiply at the nodal points in the fill assembly. This growthcan continue until complete blockage of the water flow paths through thefill unit occurs.

In like manner, unless the cooling tower water is continuously filtered,suspended solids in the make-up water from the stream or other naturalwater source can collect and accumulate in the water. These solids aretrapped by the microorganism growths in the fill assembly and increaseblockage of the water flow paths. In addition, airborne solids can buildup in the water during tower operation unless the water is filtered.

The significance of the problem is apparent when it is recognized thatin the case of a 500 megawatt power plant, if the plant must be shutdown because of blockage of the fill assembly of the cooling towerserving such plant, the loss of revenue to the utility is many thousandsof dollars per day. Replacement of the fill can take from one to twomonths. Thus, lost revenues readily mount to eight figure numbers.

The enormity of the problem is further demonstrated by the fact thatcooling towers of the type discussed and especially those used forhigh-megawatt plants such a nuclear facilities, have fill assemblieswhose plan area can be anywhere from one to four acres. Moreover,oftentimes the cooling towers of the type discussed employ hanging fillsystems which consist of wire and tube arrangements suspended from pinsor bolting systems. These current systems are very labor intensive,requiring a large amount of field labor to assemble the fill racks andto hang the fill individually from the pins in the tower. Thus, toreplace such fill can very labor intensive to remove the current filland replace it with new fill.

Accordingly, it is desirable to provide a counter-flow hanging filldesign and system that is economical and efficient to install in acooling tower. More specifically, it is desirable to provide a modularcounterflow hanging fill system that provides preassembled fill modulesthat are easily and efficiently installed in a cooling tower or thelike, reducing the labor efforts to assemble the same, and accordinglyreducing assembly costs along with reducing down time of the coolingtower when replacing said fill.

SUMMARY OF THE INVENTION

In one embodiment of the present invention, a heat exchange media fillblock is provided, comprising: a first heat exchange fill pack; a secondheat exchange fill pack; a stake, wherein said stake pierces said firstfill module and extends through said first heat exchange fill pack topierce said second heat exchange fill pack to prevent the first andsecond heat exchange fill packs from shifting with respect to oneanother.

In one embodiment of the present invention, a heat exchange media fillblock is provided, comprising: a first heat exchange fill pack; a baseframe that supports said first heat exchange fill pack; a stake, whereinsaid stake pierces said first heat exchange fill pack and extendsthrough said first heat exchange fill pack wherein said stake isreceived by said base frame.

In another embodiment of the present invention, a hanging fill supportbracket for use in a cooling tower of the like is provided, comprising:a first side having a first upper portion and a first lower portion; asecond side opposing said first side that has a second upper portion anda second lower portion; a top connect to said first and second sidesthat extends between said first and second upper portions; and a shafthaving a first and second end that extends between the first lowerportion and the second lower portion, wherein said shaft is retained byeach said first and second lower portion.

In another embodiment of the present invention, a heat exchange fillapparatus for use with a cooling tower is provided, comprising: asupport frame assembly; a media fill block, comprising: a first heatexchange fill pack; a second heat exchange fill pack; and a stake,wherein said stake pierces said first heat exchange fill pack andextends through said first heat exchange fill pack to pierce said secondheat exchange fill pack to prevent the first and second heat exchangefill packs from shifting with respect to one another; a base frame thatsupports said first heat exchange fill pack and said second heatexchange fill pack; at least one cable that extends through the mediafill block, wherein said at least one cable is connected to said baseframe; wherein said stake extends at least partially through said firstand second heat exchange fill packs and is received by the base frame; ahanging fill support bracket that attaches to said support frameassembly, said support bracket comprising: a first side having a firstupper portion and a first lower portion; a second side opposing saidfirst side that has a second upper portion and a second lower portion; atop connect to said first and second sides that extends between saidfirst and second upper portions; and a shaft having a first and secondend that extends between the first lower portion and the second lowerportion, wherein said shaft is retained by each said first and secondlower portion, wherein said at least one cable is connected to saidhanging fill support bracket.

In yet another embodiment of the present invention, a method forassembling a fill pack for use in a cooling tower is provided,comprising the steps of: placing a first fill pack on a base; placing asecond fill pack adjacent said first fill pack on the base; inserting astake through said first fill pack; optionally inserting the stakethrough said second fill pack; engaging the base with said stake toretain the first fill pack and optionally the second fill pack.

In still another embodiment of the present invention, a method forconducting heat exchange using a cooling tower is provided, comprising:passing a fluid to be cooled a fill block comprising: a first heatexchange fill pack; a second heat exchange fill pack; a stake, whereinsaid stake pierces said first fill pack and extends through said firstheat exchange fill pack to a base to prevent the first heat exchangefill pack from shifting; and generating an air current; and passing theair current over the fill block.

In another embodiment of the present invention, a heat exchange fillpack for use in a cooling tower is provided, comprising: means forplacing a first fill pack on a base; means for placing a second fillpack adjacent said first fill pack on the base; means for inserting astake through said first fill pack; optional means for inserting thestake through said second fill pack; means for engaging the base withsaid stake to retain the first fill pack and the second fill pack.

In another embodiment of the present invention, a beam bracket for usewith a cooling tower is provided, comprising: a first halve having afirst top portion, a second side wall and a first sloped portion; asecond halve having a second top portion, a second side wall and asecond sloped portion, wherein said second halve engages said firsthalve; a first bolt that engages said first top portion to said secondtop portion.

There has thus been outlined, rather broadly, certain embodiments of theinvention in order that the detailed description thereof herein may bebetter understood, and in order that the present contribution to the artmay be better appreciated. There are, of course, additional embodimentsof the invention that will be described below and which will form thesubject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of embodiments inaddition to those described and of being practiced and carried out invarious ways. Also, it is to be understood that the phraseology andterminology employed herein, as well as the abstract, are for thepurpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conceptionupon which this disclosure is based may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of hanging fill system in accordance withan embodiment of the present invention.

FIG. 2 is a detailed perspective view of the hanging fill systemillustrated in FIG. 1.

FIG. 3 is a detailed view of a connection point of the hanging fillsystem in accordance with an embodiment of the present invention.

FIG. 4 is another detailed perspective view of the hanging fill systemillustrated in FIG. 1.

FIG. 5 is a partial schematic view of the fill support system inaccordance with an embodiment of the present invention.

FIG. 6 is a detailed view of the fill support system illustrated in FIG.5.

FIG. 7 is another detailed view of the fill support system depicted inFIGS. 5 and 6.

FIG. 8 is a schematic view of a bracket apparatus in accordance withanother embodiment of the present invention.

FIG. 9 is a schematic side view of the bracket apparatus depicted inFIG. 8.

DETAILED DESCRIPTION

An embodiment of the present inventive system for a modular hanging fillsystem, generally designated 10 is illustrated. Turning specifically toFIG. 1, a modular hanging fill system 10 is illustrated having a modularfill block 12 that is comprised of multiple fill packs 22 and 24 thatform the fill block 12. The modular hanging fill system 10 includes aseries of longitudinal beams 14 and 16 having cross beams 18 extendingthere between from which the fill block 12 hangs. The longitudinal beamsand cross beams combine to form a grid like structure from which thefill block 12 hangs. The longitudinal 14, 16 and cross beams are supportby a series of columns 20. The modular fill block 12 is supported by aseries of fill supports 50 (that will be discussed in further detailbelow) that comprises an upper latching portion 52 that connects to thecross beams 18 and a lower base portion 53 upon which the fill block 12sits.

Turning now to FIG. 2, a detailed view of the bottom portion 53 of thefill support is illustrated in more detail. The bottom portion 53comprises transverse support beams 26 (one pictured) with longitudinalbeams 28 extending there between. The fill support 50, also includescable 32 that extends from the upper portion 52 to the transversesupport beam where it attaches at an attachment port 36. FIG. 2 furtherillustrates a stake 34 that extends through the fill block 12 (showntransparent for clarity) where it engages a receiving portion 37 via itsslot 38. The receiving portion 37 extends from the cross beam 28. Thestake 34 may be any conduit or rod that extends through said fill block12. While the stake 34 is depicted in a vertical orientation or normalposition, to the bottom portion 53, the stake 34 may alternatively beoriented at an angle or sloped orientation. For example, the stake 34may extend within a flute of cross-corrugated fill or the like.

Turning now to FIG. 3, a detailed end view of the transverse beam 26 isillustrated showing the support cable 32 engaging the side beam 26. Asillustrated, in one embodiment of the present invention, the supportcable 32 extends through the port 36 of the side beam 26 and engages andis connected to the said beam 26 via a bolt and loop connection. Theaforementioned bolt and loop connection includes a loop 40 at the end ofthe support cable 32 that encircles a bolt 42 that extends within theinterior of the beam 26. The bolt 42 may be secured to the beam 26 via awasher 44 and nut 45 connection. The bolt 42 may be replaced by a pin.Alternatively, the bolt or pin may be secured by a mechanical attachmentmeans, for example, weld, push caps, cotter pins or screw connection.

Turning now to FIG. 4, another detailed end view of the bottom portion53 of the support system is depicted. As illustrated in FIG. 4, thereceiving portion 37 and the slot 38 are illustrated having the stake 34inserted therein. FIG. 4 also depicts a bracket 46 that functions tosupport transverse beam 26. FIG. 4 further illustrates in detail thereceiving portion 37 having the slot 38 wherein the stake 34 is insertedtherein in combination with the cable 32 extending to engage the supportbeam 26.

Turning now to FIGS. 5 and 6, the fill support system, generallydesignated 50, is illustrated having the previously described latchingportion 52 and the previously described base portion 53. Whereas FIG. 5schematically depicts the fill support system 50 without the fill havingthe upper and lower portions, FIG. 6 is a detailed illustration of thelatching portion 52.

The latching portion 52 comprises a shaft 54 that extends between a pairof side struts 58. The side struts 58 are connected via a top portion60. In one embodiment of the present invention, the side struts 58 maycomprise two components, an upper portion that engages the top 60 and alower portion 59 through which the shaft 54 extends. Alternatively, thelatching portion may be a single, integral piece if desired. Asillustrated in FIG. 6, one embodiment of the present invention utilizesa cotter pin 62 or the like that retains the shaft 54 between the struts58. In one embodiment of the present invention, a cotter pin 62 may beused on both ends of the shaft 54 whereas other embodiments may employonly a single cotter pin 62. Alternatively, the shaft 54 may be retainedvia a compression fit or any other mechanical means or method.

As depicted in FIG. 6, and more specifically in FIG. 7, the cable 32connects or is attached to the latching portion 52 via the shaft 54 byway of an attachment loop 56. Turing specifically to FIG. 7, theattachment loop 56 has an upper curved section 64 that extends betweenfirst and second sides 66. The first and second sides 66 extendgenerally parallel to one another in opposing relationship. Theattachment loop 56 further includes a base that is comprised of an firstflap 68 and a second flap 69. As illustrated in one embodiment of thepresent invention, flap 68 and flap 69 overlap one another to form thebase of the attachment loop 56. Alternatively, in another embodiment,the base may be a solid piece and not comprise separate flaps as shown.

The cable 32 extends through the flaps 68 and 69 wherein the end 70extends into the loop 56. The end 70 may be threaded wherein it engagesa washer 72 and nut 73 on one side of the flaps 68, 69 and another nut74 and washer 75 on the other side of the flaps 68, 69. The cable 32 maybe alternatively be connected or attached to the loop 56 by anypreferred attachment means or method.

During operation, the fill block 12 is comprised of multiple individualfill packs. These individual fill packs are assembled at the factorywherein the stake 34 or multiple stakes is inserted through said packsas previously discussed. The stakes 34 may be constructed of anymaterial, for example, polyvinyl chloride (PVC) or any other preferredplastic or alternative material. The stakes 34 extend through “normal”internal paths of the fill packs and function to prevent the fillmodules from shifting or losing their shape during transportation andassembly. The stakes 34 also function to lock or anchor the fillpack(s), and thus the fill block 12, to the base frame 53. Also, in oneembodiment of the present invention, the various cables 32 that supportthe fill media may be inserted prior to shipping the fill block 12 ifdesired.

Upon the fill packs 12 arriving at the installation site, for thoseembodiments shipped with the cables installed, the cables are attachedto the base portion 53 and to the beam 26. The cable 32 is next attachedto the upper portion 52 of the fill support system 50. During theinstallation process, the upper portions 52 of the fill support system50 are typically hung from a beam or the like, similar to thatillustrated in FIG. 1, prior to the fill pack installation in the tower.The aforementioned beam is typically part of an overall, larger framestructure or the support assembly of the cooling tower. As previouslydescribed, the cable 32 engages and is attached to the upper portion 52via the loop 56 and shaft 54. Alternatively, the cable may be insertedthrough the fill media packs 12 are attached to the base portion 53 andto the beam 26 at the site. The cable 32 is then connected to the upperportion 52 of the fill support system 50. As in the embodiment describedabove, the cable 32 engages and is attached to the upper portion 52 vialthe loop 56 and shaft 54.

In this position fill block 12 maybe secured to the base 53 as neededhowever as illustrated in FIGS. 2 and 4, the stakes also assist tosecure the fill packs 12 by engaging the receiving portion 37 andinserted through the slots 38. The stake's 34 engagement with the slot38 helps to secure the fill block 12 to the base 53 of the fill supportsystem 50.

The above-described process is repeated as necessary depending upon thesize of the respective cooling tower in which the fill packs 12 areemployed. Moreover, the above-described fill system allows for the fillto be efficiently installed and replaced due to the ability to assemblethe fill packs at the manufacturing plant and ship in the pre-assembledstate. Once arriving at the cooling tower site, the individual packs areefficiently installed in the manner described above.

Turning now to FIG. 8 and FIG. 9, an alternative embodiment of thepresent invention is depicted, wherein a beam bracket generallydesignated 200 is illustrated. The beam bracket comprises two sides orhalves 202 and 204 that encircle the support beam 206 from which thefill block (not pictured) suspends. As illustrated in FIG. 8, the halves202 and 204 are retained or attached to one another via an upper or topbolt 206 and a bottom or lower bolt 208. The upper bolt 206 extendsthrough first and second top flanges 210 and 212 each corresponding to ahalve 202, 204. Similarly, the lower bolt 208 extends through first andsecond lower flanges 214 and 216 each corresponding to a halve 202, 204.

As depicted in FIG. 8, each halve comprises a top portion 218 and 220,opposing side walls 222 and 224 and sloped bottom portions 226 and 228.As illustrated, the sloped portions 226, 228 extend from each respectiveside wall 222, 224 to each respective flange 214, 216 through which thebolt 208 extends as previously described. In the embodiment illustrated,the bolt 208 may be rotated to collapse or pull together the slopedportions 226, 228 changing the angle of said sloped portions 226, 228 asindicated by FIG. 8. Alternatively, the bolt 208 may be rotated in theopposite direction, “loosening” the angle of the sloped portions 226,228. The aforementioned collapsing and releasing of the of the slopedportions 226, 228 via the bolt 208 may be used to adjust the height ofthe fill block by moving the cable upward or downward depending upon theangle of the sloped portions 226, 228.

Continuing to refer to both FIGS. 8 and 9, the lower flanges 214, 216,include a series of holes or bores 232 that allow for the cable 230 tobe attached at various heights via a bolt 234. The above-described holesor bores 232 allow for the fill block to be adjusted in terms of hangingheight.

The many features and advantages of the invention are apparent from thedetailed specification, and thus, it is intended by the appended claimsto cover all such features and advantages of the invention which fallwithin the true spirit and scope of the invention. Further, sincenumerous modifications and variations will readily occur to thoseskilled in the art, it is not desired to limit the invention to theexact construction and operation illustrated and described, andaccordingly, all suitable modifications and equivalents may be resortedto, falling within the scope of the invention.

What is claimed is:
 1. A method for assembling a fill block for use in acooling tower, comprising the steps of: placing a first heat exchangefill pack on a base; inserting a first stake through said first heatexchange fill pack; and engaging the base with said stake to retain thefirst fill pack to the base.
 2. The method according to claim 8, furthercomprising: placing at least a second heat exchange fill pack on thebase; inserting a second stake through said at least second heatexchange fill pack; engaging the base with said second stake to retainthe at least second heat exchange fill pack to the base.
 3. The methodaccording to claim 8, further comprising the steps of: placing aplurality of heat exchange fill packs on the base; inserting a pluralityof stakes through the plurality of heat exchange fill packs; engagingthe base with the plurality of stakes to retain the plurality of fillpacks.
 4. The method according to claim 8, further comprising the stepsof: inserting a cable through the first heat exchange fill pack; andattaching the cable to the base frame.
 5. The method according to claim11, further comprising the steps of: installing the heat exchange fillpacks in a cooling tower by attaching the cable to a hanging fillsupport bracket, comprising; and attaching the hanging fill supportbracket to a cooling tower beam.
 6. The method according to claim 12,wherein the hanging fill support bracket comprises: a first side havinga first upper portion and a first lower portion; a second side opposingsaid first side that has a second upper portion and a second lowerportion; a top connected to said first and second sides that extendsbetween said first and second upper portions; and a shaft having a firstand second end that extends between the first lower portion and thesecond lower portion, wherein said shaft is retained by each said firstand second lower portion.
 7. The method according to claim 12, whereinthe hanging fill support bracket comprises: a first halve having a firsttop portion, a second side wall and a first sloped portion; a secondhalve having a second top portion, a second side wall and a secondsloped portion, wherein said second halve engages said first halve; afirst bolt that engages said first top portion to said second topportion.
 8. A method for conducting heat exchange using a cooling tower,comprising: passing a fluid to be cooled of a fill block, comprising: afirst heat exchange fill pack module; a stake, wherein said stakepierces said first heat exchange fill pack and extends through saidfirst heat exchange fill pack and anchors the fill pack to a base;support bracket comprising: a first side having a first upper portionand a first lower portion; a second side opposing said first side thathas a second upper portion and a second lower portion; a top connectedto said first and second sides that extends between said first andsecond upper portions; and a shaft having a first end and a second endthat extends between the first lower portion and the second lowerportion, wherein said shaft is retained by each said first and secondlower portion; generating an air current; and passing the air currentthrough the fill block.
 9. A heat exchange fill block for use in acooling tower, comprising: means for placing a first fill pack on abase; means for placing at least a second fill pack said first fill packon the base; means for inserting a stake through said first fill pack;means for inserting the stake through said at least second fill pack;means for engaging the base with said stake to retain the first fillpack and the at least second fill pack.